Chapter 7 Mixing and Granulation

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Cody Young
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1 Chapter 7 Mixing and Granulation 7.1 Mixing and Segregation (Chapter 9) Mixing vs. segregation (1) Types of Mixture * Perfect mixing Random mixing Segregating mixing Figure 9.1 (2) Segregation 1) Causes and Consequences of Segregation - Particles with the same physical property (size, density and shape) collect together in one part of the mixture. - Usually it occurs during moving, pouring, conveying, processing - Its degree depends on particle-particle interaction* * Free-flowing powder or coarse particles segregating rather than mixing Cohesive powder or fine particles mixing rather than segregating but easily aggregating 2) Mechanisms of Separation Figure Trajectory segregation From Chapter 3 in lecture note, ρ μ Stop distance - Percolation of fine particles - Figure 9.3 Rise of coarse particles on vibration - Figure Elutriation segregation

3) Reduction of Segregation - Make the sizes of the components as close as possible - Reduce the absolute size of the particles μρ < 30 with density about = 2000-3000kg/m 3 Critical diameter lowered

2 3) Reduction of Segregation - Make the sizes of the components as close as possible - Reduce the absolute size of the particles μρ < 30 with density about = kg/m 3 Critical diameter lowered as the density increases. - Use of interparticulate forces Add a small amount of liquid (Use of liquid-bridge force) μ - Make one of the components very fine (less than 5 ) Ordered mixing* Figure Avoid to promote the segregation - Use continuous mixing for very segregating materials 4) Equipment for Particulate Mixing - Mechanisms of Mixing and Types of Mixer (9.5.1 and 9.5.2) Diffusive mixing Shear mixing C o n v e c t i v e mixing - Random walk phenomenon - Essential for microscopic homogenization - Not suitable for segregating particles - Induced by the momentum exchange of powders having different velocities - Semi-microscopic mixing - Circulation of powders by rotating blades - Beneficial for batch mode, not for continuous mixing - Suitable for segregating particles Tumbling mixers, Figure 9.6 High-velocity rotating blade Low velocity-high compression rollers, Ribbon blender, Figures 9.7,9.8 Fluidized-bed mixer * Ordered mixture by dry impact blending method

3 5) Assessing the Mixture For Binary mixture(2 components) If y i (i=1,2, N): composition of the key component in the i-th sample, Sample mean * True mean? Standard deviation, (standard variance, ) - Estimated standard variance( ) - Theoretical Limits of variance Upper limit: true standard deviation for a completely unmixed system, Lower limit: true standard deviation of random binary mixture, where : fractions of two components in the whole mixture Degree of Mixing (Mixing indices) The ratio of mixing achieved to mixing possible Lacey : Poole : Worked Example 9.1, 9.2, Size Enlargement - Granulation (Chapter 11) * Size enlargement - agglomeration of particles

4 cf. coagulation * Why enlarge the particles? - To reduce dust hazard - To reduce cake and lump formation - To increase flow properties - To increase bulk density for storage - To increase nonsegregating mixtures - To provide defined metered quantity of active ingredients - To control surface-to-volume ratio * How enlarge the particles? - Granulation: agglomeration by agitation (relative motion of particles) - Machine granulation :compaction(tabletting), extrusion - Sintering: thermal, final densification - Spray drying: starting from droplets followed by its drying - Prilling (freeze drying) (1) Interparticle Forces (11.2) 1) Van der Waals Forces - Between two spheres where : Hamaker constant : separation 2) Forces due to Adsorbed Liquid Layers - Overlapping of adsorbed layers - Dependent on area of contact and tensile strength of the adsorbed layers 3) Forces due to Liquid Bridges

5 πγ For pendular state Figure 11.1 * Strong granules in which the quantity of liquid is not critical... * Granule strength continuously decreases in funicular, capillary and droplet states. 4) Electrostatic Forces * Contact electrification: - Friction caused by interparticle collision Transfer of electrons between bodies 5) Solid bridges - Crystalline bridges - Liquid binder bridges - Solid binder bridges 6) Comparison and Interaction between Forces - Humidity vs. van der Waals forces, interparticle friction, liquid bridges and electrostatic forces Figure 11.2 Tensile strength for various bonding mechanisms (2) Granulation (11.3) - Agitation: distribute liquid binder and impart energy to particles and granules for relative motion to meet together... 1) Granulation Rate Process (11.3.2) i) Wetting - Rate of penetration of liquid

6 γθ μ where Washburn equation : average pore radius, depending on particle size and packing density packing.. θ : dynamic contact angle μ : viscosity of liquid, depending on the binder concentration ii) Growth Figure Nucleation - shatter - Coalescence - breakage - Layering - attrition - Abrasive transfer ρ μ Define Box on p274 Ennis and Litster(1997) where : coefficient of restitution : surface roughness of granules - Noninertial regime: all collisions effective for coalescence rate of wetting controls independent of liquid viscosity, granule size and kinetic energy of collision - Inertial regime: some exceeds the proportion of successful collision decreases dependent on viscosity, granule size and kinetic energy - Coating regime: average exceeds granule growth is balanced by breakage growth continues by coating of primary particles onto existing granules

7 iii) Granule consolidation - increase in granule density by closer packing density - squeeze out liquid 2) Simulation of Granule Growth (11.3.3) 3) Granulation Equipments (11.3.4) Table Tumbling granulator Figure 11.4 Tumbling inclined drum and pan Operate in continuous mode - Mixer granulator Rotating agitator From 50 rpm(horizontal pug mixer-fertilizer) to 3000 rpm(vertical Schugi high shear continuous granulator-detergent, agricultural chemicals) - Fluidized bed granulators

8 Bubbling or spouted bed Figure 11.5 Operate in batch or continuous mode Good heat and mass transfer Mechanical simplicity Combine drying stage with granulation Produce small granules Running cost and attrition rates : higher

Tendency of blends for segregation

Tendency of blends for segregation How to study it? Methods for measuring the segregation potential Louk Peffer 1 Outline/Themes Blends unmix Theory or reality Visual inspection Segregation mechanisms